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Summaries are presented for the first group of materials processing experiments planned for a shuttle mission. Outlined are the objectives, the approach, the rationale for the use of space, and the anticipated results for each experiment.
System developed to test specimens in compression as well as tension while maintaining constant bearing/bypass ration. Test specimen with centrally located hole is clamped between two bearing-guide plates using one bolt. Bearing-guide plates then secured to two bearing-load cells. Test specimen independently loaded at both ends, using two separate control systems identified as applied and bypass. If two end loads unequal, difference between them reacted as bolt-bearing load on specimen. Throughout test, two control systems synchronized by common input signal (increasing voltage). As result, loads remain proportional as they increase.
In 1984 Congress authorized NASA to begin the Space Station Program, and requested that 10 percent of program funds be spent in implementing automation and robotics (A and R) on the Space Station. In response to that request, Boeing established several Independent Research and Development (IR and D) projects to explore possible uses for A and R on the Space Station. One of those projects, and automated materials processing experiment, is discussed. The project uses a teleoperated robot to demonstrate telescience applied to a Chemical Vapor Transport materials processing experiment.
The Mars Sample Return mission will provide us with a unique source of material from our solar system; material which could advance our knowledge of the processes of chemical evolution. As has been pointed out, Mars geological investigations based on the Viking datasets have shown that primordial Mars was in many biologically important ways similar to the primordial Earth; the presence of surface liquid water, moderate surface temperatures, and atmosphere of carbon dioxide and nitrogen, and high geothermal heat flow. Indeed, it would seem that conditions on Earth and Mars were fundamentally similar during the first one billion years or so. As has been pointed out, Mars may well contain the best preserved record of the events that transpired on the early planets. Examination of that early record will involve searching for many things, from microfossils to isotopic abundance data. We propose an investigation of the returned Mars samples for biologically important organic compounds, with emphases on amino acids, the purine and pyrimidine bases, and nucleosides.
An overview is presented of potential interactions that can occur on spacecraft operating in space environments. These interactions are discussed in detail. The environment acts on spacecraft in such a way that charging of exterior surfaces occurs. The consequences from this charging then affect system operational performance. Hence, it is the coupling of this exterior charging to system performance that is of concern here. These interactions were first discovered in the spacecraft charging phenomena in which the geomagnetic substorms charged external surfaces to a level that discharges occurred. As a result of the discharge, electronic systems either changed logic state (anomalous switching) or failed. These interactions can occur in all orbits. The type associated with geosynchronous orbits is called passive since the environment provides the charging mechanism. This type can also occur in polar orbits due to auroral charging environments. In low Earth orbits, the thermal plasma alleviates charging environment concerns, but system operations can induce similar effects.
The response of composite laminates to long-term, cyclic loading conditions is dependent on mode and level of loading, material system, geometry, and laminate stacking sequence. An overview of basic damage mechanisms in notched laminates is presented. The relationships between damage and long-term response, specifically changes in residual tensile and compressive strength and life, are discussed for several composite systems with different matrix materials subjected to reversed cyclic loading.
NASA's has established long term goals for access-to-space. The third generation launch systems are to be fully reusable and operational around 2025. The goals for the third generation launch system are to significantly reduce cost and improve safety over current systems. The Advanced Space Transportation Program Office (ASTP) at the NASA's Marshall Space Flight Center in Huntsville, AL has the agency lead to develop space transportation technologies. Within ASTP, under the Spaceliner Investment Area, third generation technologies are being pursued. The Spaceliner Investment Area's primary objective is to mature vehicle technologies to enable substantial increases in the design and operating margins of third generation RLVs (current Space Shuttle is considered the first generation RLV) by incorporating advanced propulsion systems, materials, structures, thermal protection systems, power, and avionics technologies. Advancements in design tools and better characterization of the operational environment will result in reduced design and operational variabilities leading to improvements in margins. Improvements in operational efficiencies will be obtained through the introduction of integrated vehicle health management, operations and range technologies. Investments in these technologies will enable the reduction in the high operational costs associated with today's vehicles by allowing components to operate well below their design points resulting in improved component operating life, reliability, and safety which in turn reduces both maintenance and refurbishment costs. The introduction of advanced technologies may enable horizontal takeoff by significantly reducing the takeoff weight and allowing use of existing infrastructure. This would be a major step toward the goal of airline-like operation. These factors in conjunction with increased flight rates, resulting from reductions in transportation costs, will result in significant improvements of future vehicles. The real-world problem is that resources are limited and technologies need to be prioritized to assure the resources are spent on technologies that provide the highest system level benefits. Toward that end, a systems approach is being taken to determine the benefits of technologies for the Spaceliner Investment Area. Technologies identified to be enabling will be funded. However, the other technologies will be funded based on their system's benefits. Since the final launch system concept will not be decided for many years, several vehicle concepts are being evaluated to determine technology benefits. Not only performance, but also cost and operability are being assessed. This will become an annual process to assess these technologies against their goals and the benefits to various launch systems concepts. The paper describes the system process, tools and concepts used to determine the technology benefits. Preliminary results will be presented along with the current technology investments that are being made by ASTP's Spaceliner Investment Area.
NASA's has established long term goals for access-to-space. The third generation launch systems are to be fully reusable and operational around 2025. The goals for the third generation launch system are to significantly reduce cost and improve safety over current systems. The Advanced Space Transportation Program (ASTP) Office at the NASA's Marshall Space Flight Center in Huntsville, AL has the agency lead to develop space transportation technologies. Within ASTP, under the Hypersonics Investment Area, third generation technologies are being pursued. The Hypersonics Investment Area's primary objective is to mature vehicle technologies to enable substantial increases in the design and operating margins of third generation RLVs (current Space Shuttle is considered the first generation RLV) by incorporating advanced propulsion systems, materials, structures, thermal protection systems, power, and avionics technologies. The paper describes the system process, tools and concepts used to determine the technology benefits. Preliminary results will be presented along with the current technology investments that are being made by ASTP's Hypersonics Investment Area.
NASA suffered the loss of the seven-member crew of the Space Shuttle Columbia on February 1, 2003 when the vehicle broke apart upon re-entry to the Earth's atmosphere. The final report of the Columbia Accident Investigation Board (CAIB) determined that the accident was caused by a launch ascent incident-a suitcase-sized chunk of insulating foam on the Shuttle's External Tank (ET) broke off, and moving at almost 500 mph, struck an area of the leading edge of the Shuttle s left wing. As a result, one or more of the protective Reinforced Carbon-Carbon (RCC) panels on the wing leading edge were damaged. Upon re-entry, superheated air approaching 3,000 F breached the wing damage and caused the vehicle breakup and loss of crew. The large chunk of insulating foam that broke off during the Columbia launch was determined to come from the so-called bipod ramp area where the Shuttle s orbiter (containing crew) is attached to the ET. Underneath the foam in the bipod ramp area is a layer of TPS that is a cork-filled silicone rubber composite. In March 2003, the NASA Marshall Space Flight Center (MSFC) in Huntsville, Alabama received cured samples of the foam and composite for testing from the Michoud Assembly Facility (MAF) in New Orleans, Louisiana. The MAF is where the Shuttle's ET is manufactured. The foam and composite TPS materials for the ET have been well characterized for mechanical property data at the super-cold temperatures of the liquid oxygen and hydrogen fuels used in the ET. However, modulus data on these materials is not as well characterized. The TA Instruments 2980 Dynamic Mechanical Analyzer (DMA) was used to determine the modulus of the two TPS materials over a range of -145 to 95 C in the dual cantilever bending mode. Multi-strain, fixed frequency DMA tests were followed by multi-frequency, fixed strain tests to determine the approximate bounds of linear viscoelastic behavior for the two materials. Additional information is included in the original extended abstract.
During the Space Shuttle Columbia Accident Investigation, it was determined that a large chunk of polyurethane insulating foam (= 1.67 lbs) on the External Tank (ET) came loose during Columbia's ascent on 2-1-03. The foam piece struck some of the protective Reinforced Carbon-Carbon (RCC) panels on the leading edge of Columbia's left wing in the mid-wing area. This impact damaged Columbia to the extent that upon re-entry to Earth, superheGed air approaching 3,000 F caused the vehicle to break up, killing all seven astronauts on board. A paper after the Columbia Accident Investigation highlighted thermal analysis testing performed on External Tank TPS materials (1). These materials included BX-250 (now BX-265) rigid polyurethane foam and SLA-561 Super Lightweight Ablator (highly-filled silicone rubber). The large chunk of foam from Columbia originated fiom the left bipod ramp of the ET. The foam in this ramp area was hand-sprayed over the SLA material and various fittings, allowed to dry, and manually shaved into a ramp shape. In Return-to-Flight (RTF) efforts following Columbia, the decision was made to remove the foam in the bipod ramp areas. During RTF efforts, further thermal analysis testing was performed on BX-265 foam by DSC and DMA. Flat panels of foam about 2-in. thick were sprayed on ET tank material (aluminum alloys). The DSC testing showed that foam material very close to the metal substrate cured more slowly than bulk foam material. All of the foam used on the ET is considered fully cured about 21 days after it is sprayed. The RTF culminated in the successful launch of Space Shuttle Discovery on 7-26-05. Although the flight was a success, there was another serious incident of foam loss fiom the ET during Shuttle ascent. This time, a rather large chunk of BX-265 foam (= 0.9 lbs) came loose from the liquid hydrogen (LH2) PAL ramp, although the foam did not strike the Shuttle Orbiter containing the crew. DMA testing was performed on foam samples taken fiom a simulated PAL ramp panel. It was found that the smooth rind on the foam facing the cable tray did significantly affect the properties of foam at the PAL ramp surface. The smooth rind increased the storage modulus E' of the foam as much as 20- 40% over a temperature range of -145 to 95 C. Because of foam loss fiom the PAL ramp, future Shuttle flights were grounded indefinitely to allow further testing to better understand foam properties. The decision was also made to remove foam from the LH2 PAL, ramp. Other RTF efforts prior to the launch of Discovery included
The thesis of the present discussion is that the simultaneous cost and inherent safety issues of human on-site exploration of Mars will require advanced-to-revolutionary technologies. The major crew safety issues as currently identified include reduced gravity, radiation, potentially extremely toxic dust and the requisite reliability for years-long missions. Additionally, this discussion examines various technological areas which could significantly impact Human-Mars cost and safety. Cost reductions for space access is a major metric, including approaches to significantly reduce the overall up-mass. Besides fuel, propulsion and power systems, the up-mass consists of the infrastructure and supplies required to keep humans healthy and the equipment for executing exploration mission tasks. Hence, the major technological areas of interest for potential cost reductions include propulsion, in-space and on-planet power, life support systems, materials and overall architecture, systems, and systems-of-systems approaches. This discussion is specifically offered in response to and as a contribution to goal 3 of the Presidential Exploration Vision: "Develop the Innovative Technologies Knowledge and Infrastructures both to explore and to support decisions about the destinations for human exploration".
Materials International Space Station Experiment 7B (MISSE 7B) is the most recent in a series of experiments flown on the exterior of International Space Station for the purpose of determining the durability of materials and components in the space environment. A collaborative effort among the Department of Defense, the National Aeronautics and Space Administration, industry, and academia, MISSE 7B will be flying a number of NASA experiments designed to gain knowledge in the area of space environmental effects to mitigate risk for exploration missions. Consisting of trays called Passive Experiment Containers, the suitcase sized payload opens on hinges and allows active and passive experiments contained within to be exposed to the ram and wake or zenith and nadir directions in low Earth orbit, in essence, providing a test bed for atomic oxygen exposure, ultraviolet radiation exposure, charged particle radiation exposure, and thermal cycling. New for MISSE 7B is the ability to monitor experiments actively, with data sent back to Earth via International Space Station communications. NASA?s active and passive experiments cover a range of interest for the Agency. Materials relevant to the Constellation Program include: solar array materials, seal materials, and thermal protection system materials. Materials relevant to the Exploration Technology Development Program include: fabrics for spacesuits, materials for lunar dust mitigation, and new thermal control coatings. Sensors and components on MISSE 7B include: atomic oxygen fluence monitors, ultraviolet radiation sensors, and electro-optical components. In addition, fundamental space environmental durability science experiments are being flown to gather atomic oxygen erosion data and thin film polymer mechanical and optical property data relevant to lunar lander insulation and the James Web Space Telescope. This paper will present an overview of the NASA experiments to be flown on MISSE 7B, along with a summary of the thermal environment to be expected during the 1 yr mission scheduled for launch in 2009.
During my internship, I was involved in Boeing Thermal System/M&P, which handles maintenance and repairs of shuttle tiles, blankets, gap fillers, etc. One project I took part in was the revision of TPS-227, a repair process to tiles that entailed drilling out tile damage and using a cylindrical insert to fill the hole. The previous specification used minimal adhesive for application and when the adhesive cured, there would be several voids in the adhered material, causing an unsatisfactory bond. The testing compared several new methods and I analyzed the number of voids produced by each method to determine which one was most effective at eliminating void space. We revised the original process to apply a light adhesive coat to the top 25% of the borehole and a heavy coat to 100% of the insert. I was also responsible for maintaining the subnominal bond database, which records all unsatisfactory SIP (Strain Isolator Pad) bonds. I then archived each SIP physically for future referral data and statistics. In addition, I performed post-flight tile inspections for damages and wrote dispositions to have these tiles repaired. This also included writing a post-flight damage report for a section of Atlantis and creating summarized repair process guidelines for orbiter technicians.
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A coated columbium alloy material system 0.04 centimeter thick was developed which provides for increased reliability to the load bearing character of the system in the event of physical damage to and loss of the exterior protective coating. The increased reliability to the load bearing columbium alloy (FS-85) was achieved by interposing an oxidation resistant columbium alloy (B-1) between the FS-85 alloy and a fused slurry silicide coating. The B-1 alloy was applied as a cladding to the FS-85 and the composite was fused slurry silicide coated. Results of material evaluation testing included cyclic oxidation testing of specimens with intentional coating defects, tensile testing of several material combinations exposed to reentry profile conditions, and emittance testing after cycling of up to 100 simulated reentries. The clad material, which was shown to provide greater reliability than unclad materials, holds significant promise for use in the thermal protection system of hypersonic reentry vehicles.